Method of shaping a wheel

Abstract: Wheels of automobiles comprise a disc part (11) and a peripheral rim part (12). The disc part is usually formed by forging. Then, rim part is shaped by rolling. So a large workshop and many apparatuses are required to manufacture the wheel. An object of the invention is to reduce a number of the apparatus. The initial material is formed so as to combine a central disc part (11) and a peripheral annular part (12) beforehand. A first ram (3a) has a pressing surface (31) for shaping an outer side of the disc part and a peripheral surface (32) for shaping an outer rim, and a second ram (3b) has a pressing surface (33) for shaping an inner side of the disc part and a peripheral surface (34) for shaping an inner rim. The rams rotate on their axes synchronously in the same direction and press the central disc part to shape the disc part of the wheel. At the same time or after a shaping roller (4) forms the rim parts by pressing the peripheral part from the side.

Description: This invention relates to a method of shaping various types of wheels combining a disc part and a rim part which are made from materials rich in plastic deformation, for instance, aluminum alloys or magnesium alloys. Automobile wheels or transmission pulleys are formed into a disc part and a peripheral rim part which is roughly perpendicular to the disc part in a unified body. Since the rim has an annular part projecting toward out side, the wheel can be not manufactured only by single forging process. Then the prior method exhibited in the JP-A-61115641 has produced a dish-shaped prototype to the final shape by forging except an annular part. The peripheral annular part is then formed into a determined rim part by rolling formation. The conventional method of a light alloy wheel requires separate processes, one of which is a forging process for finishing the disc part to the final shape and the other is spinning process for finishing the rim part to the final shape. Thus, in the conventinal manufactual line, it is necessary that a forging apparatus and a spinning apparatus are prepared separately. Moreover it is necessary to stock semifinished items between the forging process and the spinning process. Accordingly in the prior method, a large space must be required to manufacture the wheel. And different rams are requred for the each process. Moreover since the wheel is finished to the final shape through at least two processes, it takes a long time required to produce the wheel in the final shape. Thereby the light alloy wheel can not be produce at a low price. An object of this invention is to provide a method of shaping a wheel combining a disc part and a peripheral rim part which are made from materials rich in plastic deformation in a unified body at a small space occupied by apparatuses for shaping a disc part and for shaping a rim part. Another object of this invention is to provide a method of shaping a wheel which can save the process time. A still further object of this invention is to provide a method which can reduce the number of rams. According to the present invention there is provided a method of shaping from a starting material which has plasticity a wheel having a disc part having concave and convex patterns and a rim part extending in an axial direction from a periphery of the disc part, said method comprising: a: forming from the initial material a central disc part and a peripheral annular part extending generally axially from a periphery of the central disc part, b: locating a pair of rams in facing relationship, one ram having a first pressing surface which is a negative of an outer side of the disc part and a peripheral surface which is negative of an outer rim, the other ram having a second pressing surface which is a negative of an inner side of the disc part and a peripheral surface which is negative of an inner rim, c: arranging a movable shaping roller beyond the boundary of the rams, d: locating the initial material between the rams with said peripheral annular part fitting on at least one of said rams, e: pressing the central disc part by the rams while said rams rotate on their axes synchronously in the same direction for forming the concave and convex patterns of the disc part, f: pressing the peripheral annular part by the shaping roller to form a part of the rim parts which covers at least from a part of a drop center to the outer rim, and g: finishing raw parts of the peripheral annular part by spinning, wherein the central disc part is pressed by the rams at the same time as the peripheral annular part is pressed by the shaping roller and the operation is carried out without extruding the central disc part out from between the first and second pressing surfaces. Functions of this method will be explained now. The initial material 10 is sandwiched by a pair of rams 3a, 3b. The rams press the initial material 10 in an axial direction. The material is squashed into a disc part 1. At the same time or after forming the disc part, when a shaping roller 4 moves inwardly through a stated moving route, a peripheral annular part 12 is pressed from the side direction and is shaped into a rim parts by the shaping roller 4, because the central disc part is sandwiched and roteted by the rams 3a, 3b. In this time whole of rim part may be shaped up by one shaping roller. Or at least a part of rim which covers from the outer half of the drop center to the outer rim may be shaped up first by one shaping roller and then the other rim parts may be shaped up by spinning. In this way the disc part 1 and the rim parts are formed at the same time or continuously by one apparatus. The advantages of this invention is high productivity, low production cost, short time of formation and reduced space of workshop, because the disc part 1 and the rim parts 2 of the automobile wheel are formed out of the initial material 10 at the same time or continuously by one apparatus without removing a workpiece. And because the metallic rams for forging and spinning are common, small number of metallic rams can be realized. Another method of this invention comprises the steps of tilting an axis of a metallic ram 3b from a perpendicular axis of a metallic ram 3a slightly, the ram 3b of which has about a gentle conical pressing surface 33, pressing a central disc part 11 of an initial material 10 by the rams 3a, 3b which rotate synchronously on their axes in the same direction for forming the disc part 1, and pressing a peripheral part 12 of the initial material 10 by a shaping roller 4 from the tilt side of the ram 3b with the rams 3a, 3b rotating. In the method, when the disc part 1 is formed out of the initial material 10 by pressing between the metallic rams 3a, 3b, since the ram 3b rotates on its own axis which inclines against the axis of the veertical ram 3a slightly, and since the shaping roller 4 is provided out of a boundary of the rams 3a, 3b, the disc part 1 is formed by precession. Thus, the outer surface of the disc part 1 is completed after a sectional shape of the first pressing surface 31 and an inner surface of the disc part 1 is completed after a sectional shape of the second pressing surface 33. Since a pressure in this time corresponds with a needed pressure for manufacture a part of the central disc part 11 where contacts with a very few part of the ram 3b, the forming pressure given by the rams 3a, 3b to the initial material 10 in the axial direction can be reduced. And since the pressure given by the rams 3a, 3b in the axial direction and a pressure given by the shaping roller 4 in the radius direction are act to the initial material 10 in the same time, a uneven surface of the disc part 1 is shaped correctly. The peripheral surface 32 is adapted to shape an inner surface of an outer rim and an outer surface of a flange next to the outer rim. When a generatrix of the inclined ram 3b is suitable to shape an inner surface of the inner rim and an outer surface of a flange next to the inner rim, the shaping roller 4 moves inward through a stated moving roure as the rams 3a, 3b press the initial material 10, hence, the peripheral annular part 12 can be formed into the rim parts. While, in the case of a non-inclined ram 3b and when a generatrix of the shaping roller side of the ram 3b is suitable to a shape of the inner surface of the inner rim and the outer surface of the flange next to the inner rim, a part of the inner rim is formed by the tilted ram 3b, and then the tilted ram 3b is restored to the vertical position, after then the inner rim part of the wheel is finished to a final sectional shape. Thus, since the disc part 1 can be manufactured by the precession, the needed pressure force at the time of manufacture can be reduced sharply. The invention will be more fully understood from the following description given by way of example only with reference to the several figures of the accompanying drawings in which, Fig.1 is a sectional view of an initial material put in an apparatus. Fig.2 is a sectional view of the material, the rams and a side roller at an early stage of forging. Fig.3 is a sectional view of a disc part of the matrial and the rams at a final stage of forging. Fig.4 is a sectional view of a rim part of the material and the side roller at the final stage. Fig.5 is a plan view of an outer surface of a wheel. Fig.6 is sectional view of the apparatus for putting this invention into effect. Fig.7 is a sectional view of a fixed bed and a holder. Fig.8 is a partially-sectional view of the material, the rams and the side roller of another embodiment at the process for forming the disc parts. Fig.9 is a sectional view of the material, rams and roller of another embodiment at the process for forming the rim parts. Fig.10 is a sectional view of the material, rams and another side roller at the process for forming the disc part. Embodiments of this invention are explained in accordance with figures. The apparatus has a pair of rams 3a, 3b facing each other in the vertical direction. The lower ram 3a is a rotatable one at a stated position. The upper ram 3b is movable one which is displaced up and down. A shaping roller 4 is disposed out of a sandwiched space between the rams 3a, 3b with its vertical posture keeping. The upper ram 3b is supposed by a holder 5 so as to rotates on its own axis which inclines by  degrees against the axis of the lower ram 3a. The holder 5 is lowerd in the axis direction of the ram 3a. And the holder 5 has a driving dvice 51 moving the upper ram 3b rotatably. An initial material 10 comprising a central disc part 11 and a peripheral annular part 12 is laid between the lower ram 3a and the upper ram 3b, thickness of the central disc part 11 corresponds to the thickest portion of a disc part 1 of a finished wheel or more. While, thickness in the horizontal direction of the peripheral annular part 12 is thicker than that of rim parts 2 of the finished wheel, and the width in the vertical direction of the peripheral annular part 12 is shorter than that of the finished rim parts 2. It is to be desired that a volume of the central disc part 11 is set larger than that of the disc part 1 of the finished wheel slightly, and a volume of the peripheral rim part 12 is set larger than that of the rim parts 2 of the finished wheel. The upper surface of the lower ram 3a is a first pressing surface 31 which is a negative of the outer side of the disc part 1 of a wheel. The first pressing surface 31 is shaped after the disc part 1. The disc part 1 will have concave or convex patterns as shown in Fig.5. The first pressing surface 31 must have negative patterns similar to the concave or convex patterns of the disc part 1. The relation of convex and concave portions is reverse between the first pressing surface 31 and the disc part 1. A peripheral surface 32 has the sectional shape which is a negative of a part of the inner surface of the outer rim 2a and a outer surface of a flange next to the outer rim. Similarly the upper ram 3b is shaped so as to fit to form the inner side of the disc part 1 and the inner rim 2b by rotaly forging. In this embodiment the second pressing surface 33 which faces to the inner side of the disc part 1 has been shaped into about a gentle cone. An inclination of a generatrix of the cone ( an angle against a plane falling at right angles with the axis of the upper ram 3b ) corresponds with the angle of inclination () of the axis of the upper ram 3b. Namely in this embodiment the lower left generatrix of the pressing surface 33 shown in Fig.1 is constantly at right angles to the rotation axis of the lower ram 3a, in other words, it is parallel to the rotation surface of the first pressing surface 31. A peripheral slanting surface 34 of the upper ram 3b is taperd generally. A sectional shape of the tilt side of the upper ram 3b is a negative of the inner surface of the inner rim 2b and an outer surface of a flange next to the inner rim. The shaping roller 4 is disposed at the tilt side of the upper rim 3b and outside of the interface between the upper ram 3b and the lower ram 3a. The shaping roller 4 is supported rotatably on its own axis and is movable in a radius direction or along the first peripheral surface 32 and the second peripheral surface 34 with its vertical posture keeping. In this embodiment an outer half of a drop center and an outer surface of the outer rim 2a of the rim parts 2 are formed by the shaping roller 4, while the annular flange 22 next to the inner rim 2b and a tire bead portion 23 are finished by another forming roller 40. Thus, a lower part of the shaping roller 4 has a sectional shape which is a negative of a part of the drop center and an outer surface of the outer rim 2a, while a shape of an upper part of the shaping roller 4 is about trancated cone chamferd. Fig.1 to Fig.4 demonstrate how to produce a wheel from an initial material 10. In this method the rams 3a, 3b are made to rotate synchronously and the central disc part 11 is finished into the disc part 1 first, after then the peripheral annular part 12 is finished into the rim parts 2. A sectionl shape of the initial material 10 is shaped so as to adapt to the finished wheel beforehand. The initial material 10 is laid on the lower ram 3a and then the upper ram 3b is lowered so that the initial material 10 may be is pressed by the rams 3a, 3b, as shown in Fig.1. At the same time, the shaping roller 4 comes into contact to the outer side surface of the initial material 10 so that the largest diameter portion 41 of the shaping roller 4 can coincide with the outer side surface of the central disk part 1. In this condition as shown in Fig.2, the rams 3a, 3b are made to rotate synchronously in the same rotation direction and the ram 3b is pressed downwards. At the same time, the shaping roller 4 is made to move inwardly in the radius direction. Hence the peripheral annular part 12 are pressed and the thickness of which is decreased. By continuation of this condition, the material for the central disc part 1 is filled into the concave or convex patterns of the first pressing surface 31 by the action of the precession. Namely the forming of the disc part 1 can be finished. In this time, since the material corresponding to the central disc part 11 is pressed from outside by the shaping roller 4, the material is filled into the concave or convex patterns certainly without an extrusion out of the disc part 1. Further when the shaping roller 4 is pressed against a position where an interval between the shaping roller 4 and the second peripheral slanting surface 34 is smaller than an interval between the shaping roller 4 and the first peripherl surface 32, the above mentioned effect will improve all the more. And in this time, when the shaping roller 4 is moved through the stated route, a part of the material corresponding to the peripheral annular part 12 can be shaped into an intermediate form of the rim parts 2 by pressure between the shaping roller 4 and the second peripheral slanting surface 34 and between the shaping roller 4 and the first peripherl surface 32. After then, as shown in Fig.3, the pressure of the upper ram 3b against the lower rams 3a is made to reduce to a certain extent which the disc part 1 is not crushed. In this condition, the rams 3a, 3b rotate and at the same time the shaping roller 4 comes into contact to the peropheral material in order to shape the outer half of the drop center and the outer rim 2a of the rim parts 2. After then, the inner half of the drop center and the inner rim 2b of the rim parts 2 are formed by the another forming roller 40 as shown in Fig.4. In this embodiment the sectional shape of the rim parts 2 was finished after the disc part 1 has been finished, however, almost process to shape the rim parts 2 may proceed together with the process to form the disc part 1. An apparatus shown in Fig.6 can be adapted to carry out the method of shaping the wheel in present invention. In the apparatus the upper ram 3a is suspended from a top deck 61 of a frame 6, while the lower ram 3b is founded on a fixed bed 62. A cylindrical holder 63 hanged from the top deck 61 has an opening at the bottom. The rotaly bed 50 is rotatably equipped at the bottom opening of the holder 63. The upper ram 3a is fixed to the bottom of the rotary bed 50. The holder 63 is fitted to an output shaft of the oil pressure device 64. Guide posts fixed to the holder 63 penetrate holes of the deck 61. The oil pressure device can lift or sink the holder 63. The rotary bed 50 can rotate with regard to the holder 63. A worm wheel 52 is fitted around the rotary bed 50. The holder 63 has a driving motor (not shown in the figures) with an output shaft 54 for rotating the ram 3a and a worm 53 fitted to the output shaft 54. When the driving motor rotates the worm 53, the worm wheel and the ram 3a revolve at a reduced velocity. Therefore the upper ram 3a is rotated by the driving motor and the worm gear device and is lifted up or down by the oil pressure device. The lower ram 3b is fixed on a rotary bed 59 which is furnished in a holder 65. The holder 65 is laid on the fixed bed 62. The rotary bed 59 can rotate by the driving device like the upper ram 3a. A bottom of the holder 65 and a top face of the fixed bed 62 are curved surfaces which fit to each other. Thus, the holder 65 is rotatable on the top face of the fixed bed 62. A center of the curved surface corresponds to a center of a top face of the lower ram 3b. Side plates 66 having concave 67 are provided at both side of the bottom of the holder 65 as shown in Fig.7, while protrusions 68 and 68are projected at side surfaces of the fixed bed 62. By fitting the protrusions 68 and 68 into the concaves 67, the holder 65 can be held in the fixed bed 62 surely. An oil pressure devices 69 are provided between lower portions of the side plates of the frame 6 and side portions of the holder 65 rotatably. The oil pressure device 69 inclines so that an output shaft side may be lower than a mounting portion to the frame 6. Accordingly, when the output shaft of one oil pressure device 69 is made to advance and the output shaft of the other oil pressure device 69 is made to recede, the holder 65 swings from its vertical posture on the fixed bed 62. An inclined posture of the holder 65, that is to say, an inclined posture of the lower ram 3b can be control by adjusting an angle of swing of the holder 65. A roller device 7 having a shaping roller 4 is installed on one side wall of the frame 6. One oil pressure device built in the roller device 7 can displace the shaping roller 4 in the horizontal direction and the other oil pressure device built in the roller device 7 can displace the shaping roller 4 in the vertical direction. Similarly, another roller device 8 having a forming roller 40 is installed on another side wall of the frame 6. Two oil pressure devices built in the roller device 8 can adjust the posture of the shaping roller 40 in horizontal and vertical directions. The function of the embodiment will now be explained. At first the degree of inclination of the lower ram 3b is set up by adjusting degrees of advance of each output shaft of the oil pressure devices 69. In this condition, the initial material 10 is laid on the lower ram 3b and then the upper ram 3a is lowered by the oil pressure device 64. The rams 3a, 3b press and expand the initial material 10. After then each part of the wheel can be formed by the same process as the above mentioned embodiment. In this embodiment since the posture of the lower ram 3b can be adjusted, the disc part 1 can be formed with the lower ram 3b inclined, and then the sectional shape of the rim parts 2 can be shaped with the lower ram 3b stood straight. In this method the side shape of the rams 3b which stands up vertically have been formed in coincide with the inner surface of the drop center and the inner rim 2b of the rim parts 2. As shown in Fig.8, when the lower ram 3b is inclined, the disc part 1 and a part of the rim parts 2 which covers from the drop center to the outer rim 2a are formed. After then when the lower ram 3b stands up vertically, as shown in Fig.9, the rest of the rim parts 2 which covers from the drop center to the inner rim 2b can be finished. In any case mentioned above, the angle of inclination of the lower ram 3b may be small angle, for example, in the range of 0.5 to 5 degrees. Hence, in the above mentioned method, when the lower ram 3b is setted in the vertical posture from the inclined posture, there is a small space between the outer side surface of the ram 2b and the intermediate of the rim parts 2. And the intermediate of the rim parts 2 are pressed and extended against the outer side surface of the rim 3b. Thus, the drop center and the inner rim are finished after the side shape of the lower ram 2b. In this embodiments, the forming roller 40 is a spinning processing roller, but it is possible to adapt another roller for the forming roller 40. As shown in Fig.10, a side shape of a shaping roller 44 has been formed in coincide with the drop center of the rim parts 2 and when the disc part 1 is formed by the pressure between the rams 3a, 3b, the forming roller 44 may be only pushed against the peripheral material in the horizontal direction. After then, the outer rim 2a and the inner rim 2b can be finished by the former spinning procession.

Claims: A method of shaping from a starting material which has plasticity a wheel having a disc part (1) having concave and convex patterns and a rim part (2) extending in an axial direction from a periphery of the disc part, said method comprising: a: forming from the initial material a central disc part (11) and a peripheral annular part (12) extending generally axially from a periphery of the central disc part, b: locating a pair of rams (3a, 3b) in facing relationship, one ram having a first pressing surface (31) which is a negative of an outer side of the disc part and a peripheral surface (32) which is negative of an outer rim, the other ram having a second pressing surface (33) which is a negative of an inner side of the disc part and a peripheral surface (34) which is negative of an inner rim, c: arranging a movable shaping roller (4, 40) beyond the boundary of the rams, d: locating the initial material between the rams with said peripheral annular part (12) fitting on at least one of said rams (3b), e: pressing the central disc part (11) by the rams while said rams rotate on their axes synchronously in the same direction for forming the concave and convex patterns of the disc part (1), f: pressing the peripheral annular part (12) by the shaping roller (4, 40) to form a part of the rim parts (2) which covers at least from a part of a drop center to the outer rim (2a), and g: finishing raw parts of the peripheral annular part by spinning, wherein the central disc part (11) is pressed by the rams (3a, 3b) at the same time as the peripheral annular part (12) is pressed by the shaping roller (4) and the operation is carried out without extruding the central disc part out from between the first and second pressing surfaces (31, 33). A method of shaping a wheel as claimed in claim 1, wherein an axis of one ram (3b) is tilted slightly from a perpendicular axis of the other ram (3a), the pressing surface (33) of the inclined ram (3b) is shaped into about gentle cone, and said step f comprises the step of pressing the peripheral annular part (12) of the initial material by the shaping roller from a tilt side of the tilted ram at the same time as said step e. A method of shaping a wheel as claimed in claim 1 or claim 2, wherein the shaping roller (4) has a sectional surface which is a negative of a part of the drop center and an outer surface of the outer rim (2a). A method of shaping a wheel as claimed in claim 2, wherein a sectional side shape of the peripheral surface of said inclinable ram (3b) coincides with a negative of the inner surface of the inner rim (2b) and an outer surface of a flange next to the inner rim when said ram stands vertically. A method of shaping a wheel as claimed in claim 2, wherein a sectional side shape of the peripheral surface of said inclinable ram (3b) coincides with a negative of the inner surface of the inner rim and an outer surface of a flange next to the inner rim when said ram is titled. A method of shaping a wheel as claimed in claim 1, wherein the axis of one ram (3b) is tilted slightly from a perpendicular axis of the other vertical ram (3a), a sectional side shape of the peripheral surface of the inclinable ram coincides with a negative of the inner surface of the inner rim (2b) and an outer surface of a flange next to the inner rim when said inclinable ram stands vertically, and further comprising step of adjusting a rotary axis of said inclined ram so that axes of two rams are arranged coaxially after said step e or f and before said step g. A method of shaping a wheel as claimed in claim 2, wherein the shaping roller (40) has a sectional side surface which is a negative of a part of the drop centre and an outer surface of the outer rim (2a), and the step f comprises the step of pressing the shaping roller (40) against a position where a distance between the shaping roller (40) and the peripheral surface of said inclinable ram (3b) is smaller than that between the shaping roller and the peripheral surface of the vertical ram (3a). A method of shaping a wheel as claimed in any one of claims 2, 5, or 6, wherein the inclined ram (3b) has an angle of inclination in the range of 0.5 to 5 degrees. A method of shaping a wheel, as claimed in claim 1 wherein the wheel disc part (1) has first concave and convex patterns; the initial material comprises a plastically deformable mass having a central disc part (11) with periphery and having a peripheral annular part (12) extending in a vertical direction from the periphery of the central disc part; the first and second pressing surfaces (31, 33) have second concave and convex patterns which are the negative of the first concave and convex patterns of the wheel to be formed; and the step of pressing the central disc part (11) with the rams (3a, 3b) while rotating the rams on their axes synchronously in the same direction, is carried out such that the central disc part (11) intrudes into the second concave patterns at the first and second pressing surfaces so as to form the first convex patterns and is displaced by the second convex portions so as to form the first concave patterns, both without extruding the central disc part out from between the first and second pressing surfaces.

Inventors: INATANI SHUJIRO, INATANI, SHUJIRO, INATANI, SHUJIRO, C/O RAYS ENGINEERING CO., LTD.
Applicants: RAYS ENGINEERING CO LTD, RAYS ENGINEERING CO.,LTD.
Application year: 1994
Main classification: B21D53
IPC codes: B21H1, B21J9, B21D53, B21K1